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[Retro 11]

Whats involved in puting fullsac baffles in stock pipes? do the stock baffles come out easy or do they have to be drilled?
   Retro 11

[2018_FLTRXSE]

Whats involved in puting fullsac baffles in stock pipes? do the stock baffles come out easy or do they have to be drilled?
   Retro 11

You will need a die-grinder to grind the tack welds that hold the OE baffles in... then the instructions tell you to drill to mount the new baffles securely.

[1sharprdkg]

Whats involved in puting fullsac baffles in stock pipes? do the stock baffles come out easy or do they have to be drilled?
   Retro 11

Do a search on here. There are detailed posts with pictures. A good quailty grinder will be helpful and I needed my buddy to help hold the stock muffler shell to remove after the welds were ground away. Extra hands just made it eaiser.

[Para Bellum]

Here's the link to a very helpful DIY post that many people have used to guide their removal of old baffles and installation of Fullsac baffs:

http://www.cvoharley.com/smf/index.php?topic=28086.msg455168#msg455168

Here's the link to remove a catalytic converter, JIC:

http://www.cvoharley.com/smf/index.php?topic=27814.0

HTH

[DrZ]

Just had my baffles put in by a friend......they sound great
I just ordered my x-pipe and Mastertune

[FLSTFI Dave]

The hardest part is grinding the welds out on the original baffles.  However with a little patients it is an easy job to swap out the baffles.  Well worth the effort.

[sblair]

It depends on which slip-ons you have.  The standard mufflers are welded all the way around the end.  Just send these to Steve and he will cut and install.  If you have the new CVO slip-ons then there are 2 weld tics.  You grind them, drill 1 hole and slide and bolt the new cores in.

[redrum]

just did the change yesterday was simple take your time after you grind welds tap baffle toward front of muffler
clean the rest of the weld off baffle will pull right out leave packing in place and install new baffle sounds hollow
if you take packing out.

[walstibsf]

(copied from my post in the above link "installing Fullsac baffles)

One thing I found out by experimenting with the different Dremel grinding wheels and rotary files:  if used very carefully and lightly, the tiny cutoff abrasive wheels will do the trick in 5-10 minutes whilst using the edge of them like a grinder.  I had to cut off the 'stingers' on the old stock baffles(can you say sawzall?) to get clearance at angles to allow the cutoff wheel to move around enough.  Just be very careful not to undercut(cut too deep) the muffler body, as these wheels cut very quickly.

Another thing I did was to drill two holes in the top of my work bench that have the same spacing as the muffler mounts.  Then run bolts from underneath to hold the mufflers while I worked.  (towel, pad, or rag under front of muffs to prevent scratches).  I suppose I could've built a jig like this to go in a vise, also.  I found this very secure to prevent damage to the muff bodies and provide a stable working mount. 

Be sure and wear your safety glasses and remember you've got sparks and tender.

Good luck....YMMV

Hope this helps.....

[dartman]

Whats involved in puting fullsac baffles in stock pipes? do the stock baffles come out easy or do they have to be drilled?
   Retro 11

You have been given excellent advice, Like anything else the first time is by far the hardest , this was my latest endeavor, I fitted a set of Samson Decibel Killer baffles to slip into my CVO pipes I was surprised at the nice tone at Idle, weather is to bad for a real test.

[kiwihog]

2011 roadglide ... did mine last nite  used dremel die grinder bit in an air die grinder take your time 1st baffle 30 minutes 2nd one 15 minutes read the post on cvo website referenced by steve @ fullsac .. I used 2.0 cores and left the cat in .. sounds just how I want it not worrying about performance yet but im sure steve will be getting more of my hard earn cash soon dont forget to call in  your order to get the 10 % discount

[AZMike]

Does anyone know how/if performing mods like this affects the factory or extended warranties from HD?

I'd love to do the complete Fullsac Stage 1 sleeper upgrade to my 2011 SERG but I don't know if I would do it at the cost of voiding coverage for any future warranty work that would need to be done. Especially since I spent extra $$$ for the 5 year warranty.

[HOGMIKE]

Does anyone know how/if performing mods like this affects the factory or extended warranties from HD?

I'd love to do the complete Fullsac Stage 1 sleeper upgrade to my 2011 SERG but I don't know if I would do it at the cost of voiding coverage for any future warranty work that would need to be done. Especially since I spent extra $$$ for the 5 year warranty.

Check with the dealer you do business with, usually there is NO problem, but, if there is, get another dealer, OR, you can remove whatever you install to take it back to bone stock.
JMO